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Time
Time
2 time constants
300 ipm
Motion rate
1,200 ipm
Motion rate
Motion rate
5 time constants
Time
Notice that most controls will take about five time constants to complete the acceleration.
Though variable, lets say the time constant is currently set to 100 milliseconds. The
same will be true for deceleration. This means that the machine will be accelerating for
about the first 1/2 second of motion. At the end of the command, the machine will be
decelerating for the last 1/2 second of the command (again, this is assuming five time
constants are required and each time constant is 100 ms). For lengthy motions, there will
be ample time to accelerate up to the machines rapid rate and decelerate down when the
machine comes close to the end of the motion. The longer the motion, the more distance
the machine will truly move at the full rapid rate.
As you probably know, with short rapid motions the machine will never reach its full
rapid rate (in our example, any rapid motion requiring less than one second). It will be
right in the middle of the acceleration when it determines that it must start decelerating if
it is to stop in the commanded position. The middle illustration shows this kind of
motion in graph form. Notice that the machine never came close to reaching its full rapid
rate when it begins slowing down. Though this graph is not perfect (there will be lots of
variables based upon machine size and how the related parameters will be set), notice that
the time required for this motion is about 700 ms (seven time constants). And again, the
machine never comes close to its true rapid rate.
Though it may come as a bit of a surprise, we can commonly speed up the machines
motions during short positioning movements by programming in G01 mode instead of
G00. One of the main reasons for this is that acceleration/deceleration is handled
differently when G01 is used. First of all, its done in a linear fashion (not exponential).
And second, usually only 2-3 time constants (200 - 300 ms) are required to complete
acceleration/deceleration. The right-most drawing illustrates this. Even though slower
feedrates are programmed (well be using 300 ipm), the machine will actually respond
faster in G01 mode than it will in G00 mode.
A test
Its hard to predict just what kind of improvement you can expect by programming short
movements with fast feed G01 commands as opposed to rapid motion commands. Factors
include the machine size, the rapid rate, the feedrate used, and how
acceleration/deceleration parameters are set. However, there is a test you can perform to
determine just how much you can save with a specific machine.
This first test program simulates center drilling 50 closely spaced holes. Note that the
depth of each hole is only 0.2 (0.3 actual movement) and the holes are spaced 0.5 apart)
While its rather long, you can of course use a text editor and copy-and-paste to avoid
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Drawing shows how you can rapid the drill tip right to work surface after center drilling
Believe it or not, youll have ample clearance for the drill after center drilling to rapid the
drill tip right down to the work surface. Here is an example of how much clearance
youll have. If you center drill to a 0.25 inch diameter, and if you use a 118 degree twist
drill, the drill will still have to move about 0.07 inch before it starts cutting. If you stay
0.1 away from the work surface, the tool will have to move 0.17 inch before it starts
cutting!
If you spot drill to a diameter bigger than the drill diameter (to make a chamfer for the
hole to be drilled), you can actually send the drill into the hole by the drill lead amount
(0.3 times the drill diameter for a 118 degree twist drill) and still have the chamfer
amount for clearance.
Before you are too quick to discount this technique (many programmers are a little
nervous when they hear this for the first time), go out to your machine with a stop-watch.
During the machining cycle use the stop-watch to determine just how much air cutting
time there is in the program thats running. In some cases, you can reduce the program
execution time by over 20% by applying this technique! This savings will likely justify
whatever effort and precautions you must take in order to safely implement it.
G02!
X
Additionally, if you do intend to make circular motion in any plane other than XY (XZ or
YZ), you must first command the proper plane selection (see G17, G18, and G19 later in
this module). It just so happens that G17 is initialized, meaning you never have to
program plane selection if you work exclusively in the XY plane (as most programmers
do).
Limitation of the R word
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Program:
O0005 (Program number)
N010 G54 G90 S350 M03 (Select coordinate system number one, absolute
mode, and start spindle CW at 350 RPM)
N015 G00 X-0.625 Y-0.25 (Rapid to point 1)
N020 G43 H01 Z-0.25 (Instate tool length compensation, bring tool down to
work surface)
N025 G01 X5.25 F3.5 (Feed to point 2)
N030 G03 X6.25 Y0.75 J1.0 (CCW circular motion to point 3)
N035 G01 Y3.25 (Feed to point 4)
N040 G03 X5.25 Y4.25 I-1.0 (CCW circular motion to point 5)
N045 G01 X0.75 (Feed to point 6)
N050 G03 X-0.25 Y3.25 J-1.0 (CCW circular motion to point 7)
N055 G01 Y0.75 (Feed to point 8)
N060 G03 X.75 Y-0.25 I1.0 (CCW circular motion to point 9)
N065 G00 Z0.1 (Rapid away from workpiece)
N070 G91 G28 Z0 (Return to tool change position)
N075 G28 X0 Y0 (Return to starting point in X and Y)
N080 M30 (End of program)
Notice that since all of these arcs are full 90 degree arcs, only one or the other of I and J
are required in each command.
Arc limitations
Many basic CNC courses do not acquaint novice programmers with limitations related to
how large an arc can be. The limitation has to do with how many quadrant lines your
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Witness mark
here!
Drawing shows tendency for leaving witness mark if end mill approaches right to surface
To correct this problem, most programmers will have the tool arc in to approach and arc
out to escape from the surface being machined. The next drawing shows the motion.
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Minimize
witness mark
Drawing shows arc in and out to approach to and escape from machined surfaces.
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